EP2617392A1 - Prosthesis with surfaces having different textures - Google Patents

Abstract

A joint prosthesis system has two metal implant components and a bearing. One of the metal implant components has an articulation surface for articulation with the bearing. The other metal implant component (14) has a mounting surface for supporting the bearing. One of the metal implant components includes a solid metal portion (80F) and a porous metal portion (82F). The porous metal portion has surfaces (28F, 70F, 150F) with different characteristics, such as roughness, to improve bone fixation, ease removal of the implant component in a revision surgery, reduce soft tissue irritation, improve the strength of a sintered bond between the solid and porous metal portions, or reduce or eliminate the possibility of blood travelling through the porous metal portion into the joint space.

Description

• The present invention relates generally to implantable orthopaedic prostheses, and more particularly to implantable prostheses having bearing components and others component supporting the bearing components.
• During the lifetime of a patient, it may be necessary to perform a joint replacement procedure on the patient as a result of, for example, disease or trauma. The joint replacement procedure may involve the use of a prosthesis that is implanted into one or more of the patient's bones. In the case of a knee replacement procedure, a tibial tray is implanted into the patient's tibia. A bearing is then secured to the tibial tray. The condyle surfaces of a replacement femoral component bear against the tibial bearing.
• One type of knee prosthesis is a fixed-bearing knee prosthesis. As its name suggests, the bearing of a fixed-bearing knee prosthesis does not move relative to the tibial tray. Fixed-bearing designs are commonly used when the condition of the patient's soft tissue (i.e., knee ligaments) does not allow for the use of a knee prosthesis having a mobile bearing.
• In contrast, in a mobile-bearing type of knee prosthesis, the bearing can move relative to the tibial tray. Mobile-bearing knee prostheses include so-called "rotating platform" knee prostheses, in which the bearing can rotate about a longitudinal axis on the tibial tray.
• Tibial trays are commonly made of a biocompatible metal, such as a cobalt chromium alloy or a titanium alloy.
• For both fixed and mobile-bearing knee prostheses, the tibial trays may be designed to be cemented into place on the patient's tibia or alternatively may be designed for cementless fixation. Cemented fixation relies on mechanical bonds between the tibial tray and the cement as well as between the cement and the bone. Cementless implants generally have surface features that are conducive to bone ingrowth into the implant component and rely to a substantial part on this bony ingrowth for secondary fixation; primary fixation is achieved through the mechanical fit of the implant and the prepared bone.
• Tibial components of both fixed and mobile-bearing and cemented and cementless knee arthroplasty systems are commonly modular components, comprising a tibial tray and a polymeric bearing carried by the tibial tray. The tibial trays commonly include features extending distally, such as pegs or stems. These extensions penetrate below the surface of the tibial plateau and stabilize the tibial tray component against movement. In cementless tibial implants, the outer surfaces of these extensions are typically porous to allow for bone ingrowth. For example, in the Zimmer Trabecular Metal Monoblock tibial trays, pegs with flat distal surfaces and hexagonal axial surfaces are formed completely of a porous metal. In such trays, bone ingrowth is likely to occur along all surfaces of the pegs, including the distal surfaces.
• Femoral components of such knee prosthesis systems are also designed for either cemented or cementless fixation. For cemented fixation, the femoral component typically includes recesses or cement pockets. For cementless fixation, the femoral component is designed for primary fixation through a press-fit, and includes porous bone-engaging surfaces suitable for bone ingrowth. Both designs may include pegs designed to extend into prepared holes in the femur for stabilization of the implant.
• On occasion, the primary knee prosthesis fails. Failure can result from many causes, including wear, aseptic loosening, osteolysis, ligamentous instability, arthrofibrosis and patellofemoral complications. When the failure is debilitating, revision surgery may be necessary. In a revision, the primary knee prosthesis (or parts of it) is removed and replaced with components of a revision prosthetic system.
• When the tibial or femoral implant includes extensions (such as pegs or stems) that extend into the natural bone, a revision surgery usually requires a large resection of the bone in order to dislodge the extensions from the bone. This large resection not only complicates the surgery, it also requires removal of more of the patient's natural bone than is desirable. This removal of additional bone may further compromise the bone, increase the risk of onset of bone pathologies or abnormalities, or reduce the available healthy bone for fixation of the revision implant. Moreover, the large resection usually means that a larger orthopaedic implant is necessary to fill the space and restore the joint component to its expected geometry.
• This difficulty in dislodging the primary implant components from the bones is worsened by the fact that bone also grows into the extensions. Severing these connections may be problematic since not all of these areas are easily accessible without resecting large amounts of bone.
• In implants such as the Zimmer Trabecular Metal Monoblock tibia tray, some surfaces of the porous metal portion of the tibial tray may remain exposed above the tibial plateau after implantation. These exposed porous metal surfaces may be rough and may irritate the patient's soft tissue as the patient engages in normal day-to-day activities.
• Similar issues may be presented in other types of joint prostheses.
• In one aspect, the present invention provides an orthopaedic implant component comprising a porous metal body having a bone-engaging surface and a second surface extending from the bone-engaging surface. The bone-engaging surface has a static coefficient of friction and the second surface has a lower static coefficient of friction. The body has a void space of at least 60% by volume.
• Optionally, the orthopaedic implant component may comprise a tibial tray having a solid metal portion. The porous metal body may be bonded to the solid metal portion and the bone-engaging surface of the porous metal body comprises the distal surface of the tibial tray. The second surface may extend around the periphery of the tibial tray, connecting the solid metal portion to the bone-engaging surface of the body. The second surface may include opposite portions and the porous metal body between the opposite portions of the second surface may comprise metal foam.
• The porous metal body may comprise an extension extending distally from the tibial tray to a free distal end. The free distal end of the extension may define the second surface of the porous metal body. The extension may comprise a peg spaced from the central sagittal plane of the tibial tray or a stem positioned along the central sagittal plane of the tibial tray.
• Optionally, the orthopaedic implant component may comprise a distal femoral component. The implant component may include a solid metal support portion, and the porous metal body may comprise an extension extending proximally from the tibial tray to a free proximal end. The free proximal end of the extension may define the second surface of the porous metal body. The extension may comprise a peg spaced from the central sagittal plane of the distal femoral component.
• Optionally, the orthopaedic implant component may be part of an orthopaedic implant system which includes a second implant component having a bone-engaging surface. The orthopaedic implant component may comprise an augment configured to be placed selectively against the bone-engaging surface of the second implant component.
• In another aspect, the present invention provides an orthopaedic implant component comprising a porous metal body having a bone-engaging surface and a second surface extending from the bone-engaging surface. The bone-engaging surface has a surface profile under ISO 4287 (1997) and the second surface has a different surface profile under ISO 4287 (1997). The body has a void space of at least 60% by volume.
• In another aspect, the present invention provides an orthopaedic implant component comprising a porous metal body having a bone-engaging surface and a second surface extending from the bone-engaging surface. The bone-engaging surface has a surface roughness under ISO 4287 (1997) and the second surface has a lower surface roughness under ISO 4287 (1997). The body has a void space of at least 60% by volume.
• In another aspect, the present invention provides an orthopaedic implant component comprising a porous metal body having a bone-engaging surface and a second surface extending from the bone-engaging surface. The bone-engaging surface has a surface porosity and the second surface has a lower surface porosity. The body has a void space of at least 60% by volume.
• Optionally, the implant component comprises a tibial tray having a solid metal portion, in which:
• the porous metal body is bonded to the solid metal portion;
• the bone-engaging surface of the porous metal body comprises the distal surface of the tibial tray;
• the second surface extends around the periphery of the tibial tray and connects the solid metal portion to the bone-engaging surface of the body.
• Optionally, the second surface includes opposite portions, and the porous metal body between the opposite portions of the second surface comprises metal foam.
• Optionally, the implant component comprises a tibial tray, the implant component further includes a solid metal support portion, the porous metal body comprises an extension extending distally from the tibial tray to a free distal end, and the free distal end of the extension defines the second surface of the porous metal body.
• Optionally, the extension comprises a peg spaced from the central sagittal plane of the tibial tray.
• Optionally, the extension comprises a stem positioned along the central sagittal plane of the tibial tray.
• Optionally, the implant component comprises a distal femoral component, the implant component further includes a solid metal support portion, the porous metal body comprises an extension extending proximally from the tibial tray to a free proximal end, and the free proximal end of the extension defines the second surface of the porous metal body.
• Optionally, the extension comprises a peg spaced from the central sagittal plane of the distal femoral component.
• Optionally, the implant component is part of an orthopaedic implant system including a second implant component having a bone-engaging surface and the orthopaedic implant component comprises an augment configured to be selectively placed against the bone-engaging surface of the second implant component.
• The invention also provides a method of making an orthopaedic implant component comprising obtaining a porous metal body having adjacent non-parallel surfaces. One of the adjacent non-parallel surfaces is roughened while the other non-parallel surface is machined without roughening.
• Optionally, the step of roughening one of the adjacent non-parallel surfaces comprises salt blasting the surface.
• Optionally, the method includes the step of sintering the porous metal body to a solid metal body.
• Optionally, the porous metal body comprises metal foam having a void space of at least 60% by volume.
• The metal foam may comprise titanium foam.
• The invention also provides a method of making an orthopaedic implant component comprising obtaining a porous metal body having adjacent non-parallel surfaces, each surface having a coefficient of static friction. One of the adjacent non-parallel surfaces is machined to lower the coefficient of static friction of that surface.
• Optionally, one of the surfaces is roughened to increase the coefficient of static friction of the surface.
• Optionally, the method includes the step of sintering the porous metal body to a solid metal body.
• Optionally, the porous metal body comprises metal foam having a void space of at least 60% by volume. The metal foam may comprise titanium foam.
• The present invention also provides a method of making an orthopaedic implant component comprising obtaining a porous metal body having adjacent non-parallel surfaces, each surface having a surface profile. One of the adjacent non-parallel surfaces is machined to change the surface profile of that surface.
• Optionally, one of the surfaces is roughened to change the surface profile of the roughened surface.
• Optionally, the method inlcudes the step of sintering the porous metal body to a solid metal body.
• Optionally, the porous metal body comprises metal foam having a void space of at least 60% by volume. The metal foam may comprise titanium foam.
• The present invention also provides a method of making an orthopaedic implant component comprising obtaining a porous metal body having adjacent non-parallel surfaces. Each surface has a porosity. One of the adjacent non-parallel surfaces is machined to lower the porosity of that surface.
• Optionally, one of the surfaces is roughened to increase the coefficient of static friction of the surface.
• Optionally, the method includes the step of sintering the porous metal body to a solid metal body.
• Optionally, the porous metal body comprises metal foam having a void space of at least 60% by volume. The metal foam may comprise titanium foam.
• The present invention also provides a method of making an orthopaedic implant component comprising obtaining a porous metal body having adjacent non-parallel surfaces, each surface having a roughness. One of the adjacent non-parallel surfaces is machined to lower the roughness of that surface.
• Optionally, one of the surfaces is roughened to increase the roughness of the surface.
• Optionally, the method includes the step of sintering the porous metal body to a solid metal body.
• Optionally, the porous metal body comprises metal foam having a void space of at least 60% by volume. The metal foam may comprise titanium foam.
• The present invention addresses the need for a prosthesis with a modular implant component suitable for cementless fixation that can be removed more readily from the bone in revision surgery to conserve native bone. In addition, the invention addresses the need for such an implant that minimizes soft tissue irritation.
• Embodiments of the invention are described below by way of example with reference to the accompanying drawings, in which:
• FIG. 1 is an exploded perspective view of a fixed-bearing knee prosthesis;
• FIG. 2 is a bottom perspective view of the bearing of the prosthesis ofFIG. 1;
• FIG. 3 is a perspective view of the tibial tray of the knee prosthesis ofFIG. 1;
• FIG. 4 is a bottom plan view of the tibial tray ofFIG. 1;
• FIG. 5 is a cross sectional view of the tibial tray ofFIG. 4 taken along the line 5-5 ofFIG. 4, as viewed in the direction of the arrows;
• FIG. 6 is a bottom plan view of an alternative embodiment of a tibial tray;
• FIG. 7 is a cross sectional view of the tibial tray ofFIG. 6 taken along the line 7-7 ofFIG. 6, as viewed in the direction of the arrows;
• FIG. 8 is a perspective view of a preform for the tibial tray platform portion of the porous metal portion of the tibial tray ofFIGS. 1 to 5;
• FIG. 9 is a perspective view of a set of preforms for the extensions of the porous metal portion of the tibial tray ofFIGS. 1 to 5;
• FIG. 10 is a cross sectional view of the proximal end of the peg preform ofFIG. 9 taken along line 10-10 ofFIG. 9, as viewed in the direction of the arrows;
• FIG. 11 is a cross sectional view similar toFIG. 10, showing the proximal end of the peg preform mounted on the solid metal portion of the tray;
• FIG. 12 is a perspective view of an alternative form of peg that may be used for the tibial tray or femoral component;
• FIG. 13 is a perspective view of another alternative form of peg that may be used for the tibial tray or femoral component;
• FIG. 14 is a perspective view of an alternative form of preform that may be used for the porous metal portion of the tibial tray;
• FIG. 15 is a cross sectional view of the proximal end of a portion of the preform ofFIG. 14, taken along line 15-15 ofFIG. 14, as viewed in the direction of the arrows;
• FIG. 16 is a cross sectional view of the porous metal preform ofFIG. 14, taken along line 16-16 ofFIG. 14, as viewed in the direction of the arrows;
• FIG. 17 is a bottom plan view of the solid metal preform for the tibial tray ofFIGS. 4-5, for use with the porous metal preforms ofFIGS. 8 and 9;
• FIG. 18 is a cross sectional view of the solid metal preform ofFIG. 17, taken along line 18-18 ofFIG. 17, as viewed in the direction of the arrows;
• FIG. 19 is a bottom plan view of an alternative solid metal preform, for use with the porous metal preform ofFIGS. 14 and16;
• FIG. 20 is a cross sectional view of the solid metal preform ofFIG. 19, taken along line 20-20 ofFIG. 19, as viewed in the direction of the arrows;
• FIG. 21 is an enlarged partial cross sectional view of a portion of the solid metal preform ofFIGS. 17 and 18;
• FIG. 22 is an enlarged cross sectional view of a portion of the solid metal preform ofFIGS. 19 and 20;
• FIG. 23 is a view similar toFIG. 22, showing in cross section a portion of the solid metal preform ofFIGS. 19, 20 and22 assembled with the porous metal preform ofFIGS. 14 and16;
• FIG. 24 is a bottom plan view of a tibial augment;
• FIG. 25 is a bottom plan view of the tibial augment ofFIG. 24 assembled with a tibial tray similar to that shown inFIGS. 6 and 7;
• FIG. 26 is a cross sectional view of the assembly ofFIG. 25, taken along line 26-26 ofFIG. 25, as viewed in the direction of the arrows;
• FIG. 27 is a perspective view of an ankle prosthesis;
• FIG. 28 is a cross-sectional view, similar toFIGS. 5 and7, of another tibial tray;
• FIG. 29 is an enlarged cross-sectional view of one of the studs and recesses of the metal preform ofFIG. 28;
• FIG. 30 is a cross-sectional view similar toFIG. 29, showing the proximal end of the peg preform mounted on the stud ofFIG. 29;
• FIG. 31 is a cross-sectional view similar toFIGS. 5,7 and28, of another tibial tray;
• FIG. 32 is a cross-sectional view similar toFIGS. 5,7,28 and31, of another tibial tray;
• FIG. 33A is a table comparing different surface profile parameters for two groups of green machined titanium foam metal samples;
• FIG. 33B is a table comparing different surface roughness parameters for one of the groups of the titanium foam metal samples ofFIG. 33A;
• FIG. 34A is a table comparing different surface profile parameters for two groups of salt blasted titanium foam metal samples;
• FIG. 34B is a table comparing different surface roughness parameters for one of the groups of the titanium foam metal samples ofFIG. 34A;
• FIG. 35A is a table comparing different surface profile parameters for two groups of milled titanium foam metal samples;
• FIG. 35B is a table comparing different surface roughness parameters for one of the groups of the titanium foam metal samples ofFIG. 35A;
• FIG. 36A is a table comparing different surface profile parameters for a group of ground titanium foam metal samples;
• FIG. 36B is a table comparing different surface roughness parameters for the titanium foam metal samples ofFIG. 36A;
• FIG. 37A is a table comparing different surface profile parameters for two groups of titanium foam metal samples that had been turned on one type of lathe;
• FIG. 37B is a table comparing different surface roughness parameters for both groups of the titanium foam metal samples ofFIG. 37A;
• FIG. 38A is a table comparing different surface profile parameters for a group of titanium foam metal samples that had been turned on another type of lathe;
• FIG. 38B is a table comparing different surface roughness parameters for the titanium foam metal samples ofFIG. 37A;
• FIG. 39 is a table comparing different surface profile parameters for a group of polished titanium foam metal samples;
• FIG. 40A is a bar graph comparing average Pa surface profile values for the titanium foam metal samples set forth inFIGS. 33A,34A,35A,36A,37A and38A;
• FIG. 40B is a bar graph comparing average Ra surface roughness values for the titanium foam samples set forth inFIGS. 33B,34B,35B,36B,37B and38B;
• FIG. 41 is a bar graph comparing the shear strength for samples of solid metal and porous metal assemblies sintered together, showing the effect of the varying the machining parameters used in preparing the surface of the porous metal portion that contacts the solid metal portion, with error bars indicating standard deviation;
• FIG. 42A is an image of a cross sectioned ring shear specimen showing the extent of bonding when the mating inside diameter on a titanium foam ring was machined in a way that smeared the surface porosity;
• FIG. 42B is another image of a cross sectioned ring shear specimen showing the extent of bonding when the mating inside diameter on a titanium foam ring was machined in a way that smeared the surface porosity;
• FIG. 42C is another image of a cross sectioned ring shear specimen showing the extent of bonding when the mating inside diameter on a titanium foam ring was machined in a way that smeared the surface porosity;
• FIG. 43A is an image of a cross sectioned ring shear specimen showing the extent of bonding when the mating inside diameter on a titanium foam ring was machined in a way that maintained open surface porosity;
• FIG. 43B is another image of a cross sectioned ring shear specimen showing the extent of bonding when the mating inside diameter on a titanium foam ring was machined in a way that maintained open surface porosity; and
• FIG. 43C is another image of a cross sectioned ring shear specimen showing the extent of bonding when the mating inside diameter on a titanium foam ring was machined in a way that maintained open surface porosity.
• Terms representing anatomical references, such as anterior, posterior, medial, lateral, superior, inferior etc may be used throughout this specification in relation to both the orthopaedic implants described herein and a patient's natural anatomy. Such terms have well-understood meanings in both the study of anatomy and the field of orthopaedics. Use of such anatomical reference terms in the specification is intended to be consistent with their well-understood meanings unless noted otherwise.
• Referring to the drawings,FIG. 1 shows aknee prosthesis 10 which includes afemoral component 12, atibial tray 14, and abearing 16. Theknee prosthesis 10 is a fixed bearing knee prosthesis, meaning that no movement is intended to occur between thetibial tray 14 and thebearing 16. It should be understood that the invention may also be applied to mobile bearing designs, such as rotating platform tibial trays, as well as to other joint prostheses.
• Thefemoral component 12 includes two condylar articulation surfaces: a medialcondyle articulation surface 18 and a lateralcondyle articulation surface 20. These articulation surfaces 18, 20 are solid metal. Thefemoral component 12 is configured to be implanted into a surgically prepared end of the patient's femur (not shown), and is configured to emulate the configuration of the patient's natural femoral condyles. As such, thelateral condyle surface 20 and themedial condyle surface 18 are configured (e.g., curved) in a manner which mimics the condyles of the natural femur. Thelateral condyle surface 20 and themedial condyle surface 18 are spaced apart from one another thereby defining anintercondylar articulation surface 22 therebetween. Theintercondylar articulation surface 22 defines a patella groove shaped to receive and bear against a patella implant component (not shown). Theintercondylar articulation surface 22 may comprise solid metal.
• Thefemoral component 12 also includes bone-engagingsurfaces 13, 15 opposite the articulation surfaces 18, 20, 22. Some or all of the bone-engagingsurfaces 13, 15 may comprise porous metal (as described below) conducive to bony ingrowth. Alternatively, the bone-engaging surfaces of the femoral component may include cement pockets to facilitate cementing the component to the bone.
• Thefemoral component 12 ofFIG. 1 is a cruciate retaining component, although it should be understood that the invention is applicable to cruciate substituting prosthetic knee systems as well.
• Thefemoral component 12 may include features of standard, commercially available implants, such as those available from DePuy Orthopaedics, Inc., Warsaw, Indiana, as well as those available from other suppliers of prosthetic knee systems. Thefemoral component 12 may also include features disclosed inUS-A-2010/036500,US-A-2009/032664,US-A-2009/0326667,US-A-2009/326666, andUS-A-2009/326665.
• The articulation surfaces of thefemoral component 12 may be constructed from a biocompatible metal, such as stainless steel, titanium, cobalt chromium alloy or titanium alloy, although other materials may also be used. Commonly used alloys include titanium alloy Ti-6A1-4. In one aspect of the present invention, the articulation surfaces 18, 20, 22 of thefemoral component 12 comprise a titanium alloy (such as Ti-6A1-, for example) and the bone-engagingsurfaces 13, 15 comprise titanium metal foam (such as a foam made of commercially pure titanium powder, 325 mesh (<45 µm), produced by a hydride-dehydride process and that meets the ASTM F-1580 standard, available from Phelly Materials, Inc., Bergenfield, New Jersey, Part No. THD325 for example) or a mix of such a powder with a compatible titanium alloy powder, such as Ti-6A1-4V. As discussed in more detail below, the titanium metal foam may comprise a titanium foam preform bonded to the solid titanium alloy through sintering.
• As shown inFIG. 1, the bearingcomponent 16 has aproximal articulation surface 17 and a distal mountingsurface 19 opposite theproximal articulation surface 17. Theproximal articulation surface 17 of thebearing 16 includes amedial bearing surface 21 configured to articulate with themedial condyle 18 of thefemoral component 12 and alateral bearing surface 23 configured to articulate with thelateral condyle 20 of thefemoral component 12. The bearingcomponent 16 is modular, and is assembled with thetibial tray 14 intraoperatively and secured thereto through a mechanical interlocking mechanism, as described in more detail below.
• Thebearing 16 may be made of a polymeric material. Suitable polymeric materials for thebearing 16 include ultrahigh molecular weight polyethylene (UHMWPE). The UHMWPE may comprise a cross-linked material, for example. Techniques for crosslinking, quenching, or otherwise preparing UHMWPE are disclosed in documents such asUS-5728748,US-5879400,US-6017975,US-6242507,US-6316158,US-6228900,US-6245276 andUS-6281264. The UHMWPE of the bearing material may be treated to stabilize any free radicals present therein, such as through the addition of an antioxidant such as vitamin E. Techniques for stabilizing UHMWPE with antioxidants are disclosed in, for example,US-A-2007/0293647 andUS-A-2003/021216. It should be understood that the present invention is not limited to any particular UHMWPE material or to UHMWPE material for thebearing 16. It is expected that other materials for thebearing 16 are or will become available that will be useful in the invention.
• Thetibial tray 14 includes aplatform 24 having a solid metal proximal mountingsurface 26 and an opposite distal bone-engagingsurface 28. Thetibial tray 14 also includes a plurality ofextensions 30, 32, 34, 36, 38 extending distally from the distal bone-engagingsurface 28 of the platform to distal ends 40, 42, 44, 46, 48 alonglongitudinal axes 50, 52, 54, 56, 58 intersecting thedistal surface 28 of theplatform 24. Eachextension 30, 32, 34, 36, 38 has an axial length, shown, for example, as L₁ and L₂ inFIG. 5 and a thickness, shown, for example, as T₁ and T₂ inFIG. 5.
• Thefemoral component 12 may also include extensions. For example, pegs may extend proximally from the bone-engagingsurfaces 13, 15 of thefemoral component 12. One such peg is shown inFIG. 1 at 39. This peg also has a thickness and a length.
• In the femoral component and tibial tray shown in the drawings, eachextension 30, 32, 34, 36, 38, 39 extends outward from a junction with the bone-engagingsurfaces 13, 15, 28 of theirrespective implant components 12, 14 to their opposite ends 40, 42, 44, 46, 48, 51. Examples of such junctions are shown inFIG. 1 at 69, inFIG. 5 at 60, 62 and 66 and inFIG. 7at 60A, 62A, 66A. Theextensions 30, 32, 34, 36, 38, 39 have exposed outer surfaces past the junctions; examples of such exposed outer surfaces are shown at 79 inFIG. 1, at 70, 72 and 76 inFIG. 5 and at 70A, 72A and 76A inFIG. 7.
• Theextensions 30, 32, 34, 36, 38 of the first and second tibial tray embodiments define astem 30, 30A and four spacedpegs 32, 34, 36, 38, 32A, 34A, 36A, 38A. Thestem 30, 30A and pegs 32, 34, 36, 38, 32A, 34A, 36A, 38A are configured to be implanted into a surgically prepared end of a patient's tibia (not shown) and are configured for stabilizing thetibial component 14, 14A when implanted in a bone of a patient. Thestem 30, 30A is generally in the central sagittal plane of the tibial component, and thepegs 32, 34, 36, 38, 32A, 34A, 36A, 38A are spaced from the central sagittal plane of the tibial component.
• Thestem 30, 30A may be shaped as a standard stem for tibial trays, tapering from thejunction 60, 60A with the bone-engagingsurface 28, 28A of thetibial tray 14, 14A to itsdistal end 40, 40A. Each of the tibial pegs 32, 34, 36, 38 in the embodiment ofFIGS. 1,4 and 5 is circular in transverse cross-section and end view. Other shapes may also be used for the pegs. The pegs may be tapered or cylindrical. The pegs may be a combination of shapes, such as a combination of cylindrical and hexagonal, as shown inFIG. 12 at 32B. Alternatively, the pegs may be hexagonal in cross-section and end view, as shown inFIG. 13 at 32C. InFIGS. 12 and 13, the reference numbers are the same as those used in the description of the embodiment ofFIGS. 1,4 and 5 for similar parts, followed by the letters "B" and "C".
• The distal end surfaces of the stem and pegs could be flat, spheroidal or some other shape. In the embodiment ofFIGS. 1,4 and 5, the free ends 40, 42, 44, 46, 48, 51 are generally spheroidal. In the embodiments ofFIGS. 12 and 13, the distal ends 42B, 42C are flat. It should be understood that pegs and stems having other shapes might be used.
• Another embodiment is shown inFIGS. 6 and 7, where the same reference numbers have been used as those used in describing corresponding or similar parts in the embodiment ofFIGS. 1,4 and 5, followed by the letter "A". As described in more detail below, in the embodiment ofFIGS. 6 and 7, all of theextensions 30A, 32A, 34A, 36A, 38A are part of a single integral preform. The embodiments may share features as described above and below. Differences between the embodiments are described above and below.
• Thetibial trays 14, 14A illustrated inFIGS. 1 and3 to 7 are composites of two materials; eachtray 14, 14A includessolid metal portions 80, 80A andporous metal portions 82, 82A. Thesolid metal portions 80, 80A of thetibial trays 14, 14A define the proximal mounting surfaces 26, 26A of theplatforms 24, 24A and bear against the distal mountingsurface 19 of the bearingcomponent 16 when assembled. The femoral component ofFIG. 1 may also be a composite of asolid metal portion 81 and aporous metal portion 83, with thesolid metal portion 81 defining the articulatingsurfaces 18, 20, 22.
• Theporous metal portions 82, 82A, 83 of thetibial tray 14, 14A andfemoral component 12 define the distal bone-engagingsurfaces 28, 28A of thetibial platform 24, 24A and the bone-engagingsurfaces 13, 15 of thefemoral component 12. These porous metal bone-engagingsurfaces 13, 15, 28, 28A face the bone of the resected proximal surface of the tibial plateau and resected surfaces of the distal femur when implanted, and define a material that is conducive to bone ingrowth to allow for uncemented fixation of thetibial platform 24, 24A to the proximal tibia and thefemoral component 12 to the distal femur. As described in more detail below, theporous metal portion 82, 82A of thetibial tray 14, 14A extends proximally from the distal bone-engagingsurface 28, 28A and is sintered to thesolid metal portion 80, 80A at a location between the distal bone-engagingsurface 28, 28A and the proximal mountingsurface 26, 26A of theplatform 24, 24A. Thefemoral component 12 is similarly constructed, with theporous metal portion 83 sintered to thesolid metal portion 81 at a location between the bone-engagingsurfaces 13, 15 and the articulatingsurfaces 18, 20, 22.
• Theporous metal portions 82, 82A, 83 of thetibial tray 14 andfemoral component 12 may comprise preforms or a plurality of preforms. A first example of a set of porous metal preforms for atibial tray 14 is shown inFIGS. 8 and 9. This set of porous metal preforms includes abase preform 85 with anupper surface 86 opposite from the distal bone-engagingsurface 28. Theupper surface 86 becomes the interface with thesolid metal portion 80 of thetibial tray 14 when the porousmetal base preform 85 is sintered to thesolid metal portion 80 to make thetibial tray 14. As described in more detail below, the first illustratedbase preform 85 includes a plurality of smooth cylindrical bores oropenings 87, 89, 91, 93, 95 extending from theupper surface 86 to the distal bone-engagingsurface 28.
• As shown inFIG. 9, theextensions 30, 32, 34, 36, 38 in the first set of porous metal preforms are discrete components, separate from thebase preform 85 before being sintered together. The extension preforms are circular in transverse cross-section, with diameters substantially the same as the diameters of thebores 87, 89, 91, 93, 95 in thebase preform 85. Portions of the extensions adjacent to the proximal ends of the extensions fit through thebores 87, 89, 91, 93, 95 and make contact with the walls of the base preform so that thepreform 85 andextensions 87, 89, 91, 93, 95 may be sintered together. The proximal ends of the discrete extensions includeblind bores 41, 43, 45, 47, 49 aligned along thelongitudinal axes 50, 52, 54, 56, 58 of theextensions 30, 32, 34, 36, 38. Thebores 41, 43, 45, 47, 49 are threaded in this embodiment. For clarity of illustration,FIG. 9 does not show the threads in thesebores 41, 43, 45, 47, 49. An example of such a threadedbore 49 is shown in longitudinal cross-section inFIG. 10.
• Other shapes of extensions may be used in combination with thebase preform 85. For example, the extensions corresponding to the pegs may comprise a combination of a cylindrical portion and a portion that is hexagonal in transverse cross-section. Such a peg is shown inFIG. 12at 32B; the cylindrical portion is shown at 100 and the hexagonal portion is shown at 102. This peg preform also has aflat end surface 42B opposite theend surface 106 that includes the threaded bore 43B.
• Another example of an extension that may be used in the present invention is shown inFIG. 13 at 32C. In this example, theextension 32C is hexagonal in transverse cross-section and in end view. The extension includes twoflat ends 42C, 106C with ablind bore 43C in oneend 106C. In this example, theblind bore 43C is not threaded. Instead, the walls of thebore 43C define a Morse taper bore for receipt of a Morse taper post as described in more detail below. The walls defining thebore 43C may be tapered at an angle of, for example 3 to 5°. The bore is widest at theend 106C and most narrow between theend 106C and theend 42C. Peg preforms such as those illustrated inFIG. 13 could be used with a tibial platform preform similar to that illustrated inFIG. 8, except the bores or holes 89, 91, 93, 95 would have hexagonal shapes to receive and hold theextension 32C.
• An example of a porous metal preform utilizing extensions shaped like those ofFIG. 13 is shown inFIG. 14. In this example, theporous metal preform 84A includes abase portion 85A andintegral extensions 30A, 32A, 34A, 36A, 38A. Theextensions 32A, 34A, 36A, 38A correspond with pegs and theextension 30A corresponds with the stem of the tibial tray. In this embodiment, theextension 30A corresponding with the stem is circular in transverse cross-section, although it should be understood that other shapes may be used. On the proximal side of thebase 85A, an annular raisedportion 29A, 31A, 33A, 35A, 37A of each extension extends above the planarproximal surface 86A of thebase 85A. Each extension includes a longitudinal bore oropening 41A, 43A, 45A, 47A, 49A. As discussed above with respect toFIG. 13, in this embodiment, the longitudinal bores oropenings 41A, 43A, 45A, 47A, 49A are Morse taper bores tapering in a distal direction. An enlarged cross-sectional view of one of the annular raisedportions 37A and its associatedbore 49A is shown inFIG. 15 as an illustrative example; thewalls 110, 112 defining thetapered bore 49A may be angled at any suitable angle for a Morse taper bore, such as, for example, 3 to 5°. Theannular projections 29A, 31A, 33A, 35A, 37A may be cylindrical in shape, like that shown at 29A, or may have some other shape, such as the hexagonal shape (in transverse cross-section and plan view) like those shown at 31A, 33A, 35A and 37A.
• A cross-section of theporous metal preform 84A is shown inFIG. 16 as an example. Theporous metal preform 84A can be made as a single, integral piece in the moulding process and can be otherwise processed in standard ways, such as by machining to create particular features.FIG. 7 illustrates thepreform 84A ofFIGS. 14 to 16 in combination with asolid metal portion 80A to form thetibial tray 14A.
• Referring back to thesolid metal portion 80 of thetibial tray 14, a first example of adistal surface 120 of the solid metal portion is shown inFIG. 17. Thedistal surface 120 is opposite the proximal mountingsurface 26 of theplatform 24 of thetibial tray 14 ofFIG. 1. As there shown, thedistal surface 120 includes a plurality ofrecesses 122, 124, 126, 128, 130. Astud 132, 134, 136, 138, 140 is present within eachrecess 122, 124, 126, 128, 130. The distal surface of a second example of thesolid metal portion 80A of a tibial tray is shown inFIG. 19. As there shown, thedistal surface 120A also includes a plurality ofrecesses 122A, 124A, 126A, 128A, 130A. Astud 132A, 134A, 136A, 138A, 140A is present within eachrecess 122A, 124A, 126A, 128A, 130A.
• Therecesses 122, 124, 126, 128, 130 in the embodiment ofFIGS. 17 and 18 are configured to receive the cylindrical ends of theextensions 30, 32, 34, 36, 38 and thestuds 132, 134, 136, 138, 140 are threaded and complementary to the threaded bores 41, 43, 45, 47, 49 so that theextensions 30, 32, 34, 36, 38 may be threaded onto thestuds 132, 134, 136, 138, 140 to mount the extensions to thestuds 132, 134, 136, 138, 140. Preferably, therecesses 122, 124, 126, 128, 130 andextensions 30, 32, 34, 36, 38 are shaped so that there is metal-to-metal contact between the outer surfaces of theextensions 30, 32, 34, 36, 38 and the walls defining therecesses 122, 124, 126, 128, 130 so that theextensions 30, 32, 34, 36, 38 may be sintered to thesolid metal portion 80.
• Therecesses 122A, 124A, 126A, 128A, 130A in the embodiment ofFIGS. 19-20 are configured to receive the annular raisedportions 29A, 31A, 33A, 35A, 37A of thepreform 84A (or ends of theextensions 30A, 32A, 34A, 36A, 38A) and thestuds 132A, 134A, 136A, 138A, 140A are tapered and complementary totapered bores 41A, 43A, 45A, 47A, 49A so that thepreform 84A may be frictionally mounted onto thestuds 132A, 134A, 136A, 138A, 140A. Therecesses 122A, 124A, 126A, 128A, 130A and annular raisedportions 29A, 31A, 33A, 35A, 37A have complementary shapes (hexagonal in transverse cross-sections) so that there is metal-to-metal contact between the annular raisedportions 29A, 31A, 33A, 35A, 37A and the walls defining therecesses 122A, 124A, 126A, 128A, 130A so that thepreform 84A may be sintered to thesolid metal portion 80A.
• Examples of configurations for studs are shown inFIGS. 21 and 22. The studs may be threaded, such asstud 134 shown inFIG. 21 to allow for a threaded connection between the studs and the corresponding threaded bores of the extensions; such a connection is shown inFIG. 11, where threadedstud 134 is shown connected withextension 38 through such a threaded connection.
• The studs may alternatively comprise Morse taper posts having a Morse taper (generally about 3 to 5°); such a stud is shown inFIG. 22 at 134A. Generally, the studs are sized, shaped and positioned to be received within the Morse taper bore (generally about 3 to 5°) of a corresponding extension so that the extensions may be mounted on the studs. Such a connection is shown inFIG. 23, whereMorse taper stud 134A is shown engaged with Morse taper bore 41A inpreform 84A. It should be understood that the mounting mechanisms shown inFIGS. 21 and 22 are provided as examples only; other suitable structures may be used for mounting theextensions 30, 32, 34, 36, 38 and preform 84A to the correspondingsolid metal portion 80, 80A.
• In the embodiments ofFIGS. 5,7,11,18 and20 to 23 thestuds 134, 134 have free ends 135, 135A that do not extend beyond the plane of thedistal surface 120, 120A of thesolid metal portion 80, 80A of thetibial tray 14, 14A. An alternative embodiment of a tibial tray with longer studs is shown inFIGS. 28 to 30, where the same reference numbers have been used as those used in describing corresponding or similar parts in the embodiments ofFIGS. 1,4 to 7,11,18 and20 to 23 followed by the letter "D". In the embodiment ofFIGS. 28 to 30, the free ends 135D of the studs extend beyond the plane of thedistal surface 120D of thesolid metal portion 80D of thetibial tray 14D. When assembled with theporous metal portion 82D as shown inFIGS. 28 and30, the free ends 135D of the studs extend to the plane of the bone-engagingsurface 28D of the porous metal portion of thetibial tray 14D.
• In addition, it should be understood that the complementary mounting structures may be reversed, with the studs being present on the extensions and the complementary recesses being provided on the solid metal portion of the tibial tray.
• The configuration of the proximal mountingsurface 26, 26A of thesolid metal portion 80, 80A of thetibial tray 14, 14A may vary depending on the type of implant. For example, if the prosthesis is a rotating platform type of mobile bearing knee prosthesis, the proximal mountingsurface 26, 26A of thetibial tray 14, 14A and the distal mountingsurface 19 of thebearing 16 will be smooth to allow for rotation of the bearing on the proximal mountingsurface 26, 26A of thetibial tray 14, 14A. The embodiment shown inFIG. 1 is a fixed bearing design; the proximal mountingsurface 26 of thetibial tray 14 and the distal mountingsurface 19 of the bearing 16 in this embodiment include complementary locking features that eliminate or at least minimize any relative movement between the bearing 16 and thetibial tray 14 when these components are assembled. These complementary locking features in this embodiment includepedestals 154, 158,tabs 160, 162 and recesses 178, 180 on the distal mountingsurface 19 of thebearing 16 and buttresses 184, 186 and undercuts 194, 196, 198 on the proximal mountingsurface 26 of thesolid metal portion 80 of thetibial tray 14. Detailed descriptions of this and other designs for fixed bearing tibial trays may be found in, for example,US-7628818 andUS-A-2009/0082873.
• Preferably, thesolid metal portion 80, 80A of thetibial tray 14, 14A is a solid metal preform, made from a standard titanium metal alloy. A suitable alloy for this purpose is Ti-6A1-4V. This alloy is advantageous in that it may be sintered to a porous metal portion made from commercially pure titanium powder. This same material may be used for the solid metal portion of thefemoral component 12 as well. It should be understood that some of the advantages of the present invention may be achieved with other materials, including for example a standard cobalt chromium molybdenum alloy.
• Preferably, theporous metal portion 82, 82A of thetibial tray 14, 14A is a titanium metal foam. Such a foam may be made as disclosed inUS-A-2008/0199720,US-A2010/0098574,US-A-2009/0326674 andUS-A-2009/0292365. The titanium metal powder used to make theporous metal portion 82, 82A may comprise commercially pure titanium powder ( such as a titanium powder, 325 mesh (<45 µm), produced by a hydride-dehydride process and that meets the ASTM F-1580 standard, available from Phelly Materials, Inc., Bergenfield, New Jersey, Part No. THD325 for example) or a mix of such a powder with a compatible titanium alloy powder, such as alloy Ti-6A1-4V. This material is advantageous in that it can be sintered to a titanium alloy such as Ti-6A1-4V. It is expected that other grades of commercially pure titanium may be used as well and that other powder metal materials may be available or developed in the future that can provide at least some of the advantages of the present invention.
• Although titanium foam is preferred, some of the advantages of the present invention may be achieved with alternative materials as well. One example of a suitable alternative material is tantalum porous metal, for example as disclosed inUS-5282861. Another example of an alternative is a solid metal body made from an implantable metal such as stainless steel, cobalt chromium alloy, titanium, titanium alloy or the like and with a porous coating disposed on both the bone-engaging surface and the surface engaging the polymer portion of the tibial tray. One type of porous coating which may be used as theporous portion 82, 82A of thetibial tray 14, 14A is that used on products sold by DePuy Orthopaedics Inc of Warsaw Indiana under the trade mark Porocoat. Theporous metal preform 84A may be made using any of the process described above or using other processes.
• To make thetibial tray 14, 14A of the invention, thesolid metal portion 80, 80A may be made as a solid metal preform by conventional methods, such as by casting, machining or some combination of casting and machining. Such processes may also be used to make a solid metal preform for thefemoral component 12. For either thetibial tray 14, 14A or thefemoral component 12, therecesses 122, 124, 126, 128, 130, 122A, 124A, 126A, 128A, 130A, and posts orstuds 132, 134, 136, 138, 140, 132A, 134A, 136A, 138A, 140A may be machined into the solid metal preforms. For studs of the type shown inFIG. 21, threads may be formed in thestuds 132, 134, 136, 138, 140 as well. For studs of the type shown inFIG. 22, the outer surface of thestuds 132A, 134A, 136A, 138A, 140A may be shaped to define a Morse taper post.
• It is expected that the articulation and mountingsurfaces 18, 20, 26 of the solid metal portions of the femoral andtibial components 12, 14 may be treated to increase the lubricity, such as through Type II hard anodization.
• Theporous metal portion 82, 82A of thetibial tray 14, 14A andfemoral component 12 may be made by moulding the desired shape, for example using processes as disclosed inUS-A-2008/0199720 andUS-A-2010/098574. Preforms so made can have, for example, a bulk porosity (or percent open area or void space) of from about 60% to about 85% (preferably about 65% to about 75%) as measured by volume, the forced intrusion of liquid mercury, and cross-section image analysis. This porosity/void space corresponds with a preform having a density of 15 to 35% (preferably 25 to 35%) of theoretical density for a similarly sized and shaped solid metal component. It should be understood that the porosity can be a product of various factors in the manufacturing process, such as the size of pore forming agent used. The resultant titanium metal foam may be treated to increase its roughness, such as by etching or blasting, as discussed in more detail below.
• The moulds used for preparing theporous metal portion 82A may be shaped so that the resultant product defines a single, integralporous metal preform 84A such as that shown inFIG. 16. Such a preform can be used to make atibial tray 14A such as that shown inFIGS. 6 and 7. Alternatively, a plurality of moulds may be provided to make individual anddiscrete extensions 30, 32, 34, 36, 38 and an individual anddiscrete base 85 for the embodiment ofFIGS. 4, 5,9 and 9. Thebores 41, 43, 45, 47, 49, 41A, 43A, 45A, 47A, 49A in these components may be formed as part of the moulding process or machined into the finished metal foam construct. For extensions of the type shown inFIGS. 5 and9 to 12, threads may be formed in the walls defining thebores 41, 43, 45, 47, 49. For extensions of the type shown inFIGS. 7,13 to 16 and23, the walls defining thebores 41A, 43A, 45A, 47A, 49A may be tapered to define Morse taper bores.
• Theporous metal portion 82, 82A of the implant component and thesolid metal portion 80, 80A of the implant component may then be assembled. For example, for an implant component of the type shown inFIGS. 6 and 7, theintegral preform 84A may be pressed onto thedistal surface 120A of thesolid metal portion 80A, with theMorse taper studs 132A, 134A, 136A, 138A, 140A of thesolid metal portion 80A pushed into the Morse taper bores 41A, 43A, 45A, 47A, 49A of thepreform 84A, and with the annular raisedportions 29A, 31A, 33A, 35A, 37A of theporous metal preform 84A received in therecesses 122A, 124A, 126A, 128A, 130A surrounding thestuds 132A, 134A, 136A, 138A, 140A of the solid metal portion or preform 80A, as shown inFIGS. 7 and22. The Morse taper frictional connection between the studs and the bores should hold the assembly together until sintering is complete. For an implant component of the type shown inFIGS. 4 and 5, eachporous metal extension 30, 32, 34, 36, 38 may be individually assembled with thesolid metal base 80 by threading the threaded bore 41, 43, 45, 47, 49 of eachporous metal extension 30, 32, 34, 36, 38 onto the threadedstud 132, 134, 136, 138, 140 of the solid metal portion or preform 80 until the annular end of the extension is received in therecess 122, 124, 126, 128 130 surrounding thestud 132, 134, 136, 138 as shown inFIG. 11. This threaded connection between thestuds 132, 134, 136, 138 and thebores 41, 43, 45, 47, 49 should hold the assembly together until sintering is complete. It should be understood that the Morse taper connection and threaded connection described above are two examples of complementary structures for connecting the porous metal extensions to the solid metal portion of the tray; other types of connections may be used.
• The assembly of thesolid metal portion 80, 80A, 81 and theporous metal portions 82, 82A, 83 may then be sintered together to form thefinal tibial tray 14, 14A orfemoral component 12. Sintering may be accomplished utilizing the same temperatures and times used to form the porous metal portion. For example, as disclosed inUS-A-2008/199720, the assembly may be sintered under the following conditions to form the final implant component: heating at temperatures of from about 1149°C to about 1482°C (2100°F to 2700°F), preferably about 1371 °C (2500°F) for about 2 h to about 10 h (preferably about 3 h to about 6 h). The sintered part may then be cooled following an appropriate cooling cycle.
• For both the femoral and tibial components, once assembled, theporous metal portion 82, 82A, 83 defines the bone-engagingsurfaces 13, 15, 28, 28A of theimplant component 12, 14, 14A. In addition, for both the femoral and tibial components, thesolid metal portions 80, 80A, 81 contact thebearing 16, both on the mountingside 19 and thearticulation side 17.
• As mentioned above, in some situations, it may be desirable to treat theporous metal portion 82, 82A, 83 to selectively increase the roughness of some or all of the bone-engaging surfaces. Theporous metal portion 82, 82A, 83 may be treated through etching or blasting, for example, to increase the roughness of the outer surface, for example using a technique such as those as disclosed inUS-A-2009/0326674 andUS-A-2009/292365. Although the etching and blasting techniques disclosed in those documents are advantageous for use with titanium metal foams, it should be understood that the techniques disclosed in these documents are provided as examples only. Such roughening is expected to make the treated surfaces more conducive to bone ingrowth to improve ultimate fixation of the components.
• One application of the etching and blasting roughening techniques disclosed in these documents is to roughen theporous metal portions 82, 82A, 83 of thetibial tray 14, 14A andfemoral component 12. In addition, it may be advantageous to roughen selectively certain surfaces of theporous metal portion 82, 82A, 83 while leaving other surfaces in their as-machined state, with lower roughnesses, or while further treating these other surfaces to decrease the roughness of these other surfaces. Specifically, to facilitate removal of either thetibial tray 14, 14A or thefemoral component 12 from the bone in revision surgery, it may be desirable to discourage bone ingrowth at the distal ends 40, 42, 44, 46, 48, 40A, 42A, 44A, 46A, 48A of the tibial extensions and proximal ends 51 of thefemoral extensions 39. This may be accomplished by selectively roughening the distal bone-engagingsurface 28, 28A of the platform and the outer surfaces of theextensions 30, 32, 34, 36, 38, 30A, 32A, 34A, 36A, 38A at thejunctions 60, 62, 66, 69, 60A, 62A, 66A and adjacent surfaces while leaving theends 40, 42, 44, 46, 48, 40A, 42A, 44A, 46A, 48A opposite thejunctions 60, 62, 66, 69, 60A, 62A, 66A (and some adjacent surfaces if desired) in the as-machined state.
• A variety of other techniques are known for treating porous metal implants and may be applied to the present invention. For example, calcium phosphate coatings (such as hydroxyapatite) may be applied to some or all of the porous portions of the embodiments of the present invention, with or without additional therapeutic agents, as disclosed inUS-A-2006/0257358 . Alternatively, electrophoretic deposition of a material such as calcium phosphate may be used.
• Alternatively, or additionally, the surfaces of theporous metal portion 82, 82A where bone ingrowth is undesirable may be machined, milled, polished or otherwise smoothed to reduce the roughness and/or porosity of the surface. Machining, milling, polishing or smoothing can be expected to close some or all of the pores and change the surface profile, thereby lowering the coefficient of friction along the surface. For example, the surfaces where bone ingrowth is undesirable may be machined with a standard carbide tip rotating at a standard speed, such as 600 rpm. Machining may be carried on until the surface is smeared and has a solid rather than porous appearance; about 0.38 mm (0.015 inch) of material may be removed in this process. It should be understood that a commercial manufacturing process may be run under different parameters. Machining, milling, polishing or smoothing can be accomplished when the component is in the green state, before sintering, after sintering, or both before and after sintering.
• Alternative methods of producing surfaces with lower surface roughnesses and lower static coefficients of friction may be used. For example, pores may be selectively filled with metal. As another alternative, when moulding the porous metal portion of the implant or the pegs and stem, or when sintering the solid metal and porous metal portions together, solid metal pieces may be sintered to the free ends of the pegs and stems. Another alternative would include moulding a non-porous biocompatible polymer cap to the ends of the extensions; an example of such a polymer is polyetheretherketone (PEEK).
• Thus, various techniques are available for selectively roughening, smoothing and changing the porosity of surfaces of the porous metal portions of the implants.
• The porosity and roughness of other surfaces may also be modified. Considering the embodiment ofFIGS. 1 and3, for example, there are surfaces of theporous metal portion 82 that are not intended to engage bone or another part of the implant component. An example of such a surface is exposed peripheral surface 150 of theporous portion 82 of thetibial tray 14. This exposed peripheral surface 150 extends generally perpendicularly from the distal bone-engagingsurface 28 to theupper surface 86 of theporous base 85 in the embodiment ofFIGS. 1,3 and5. At least some of this exposed peripheral surface can be expected to be engaged by soft tissue when implanted. If this exposed peripheral surface is rough, adjacent soft tissue could be irritated when the tray is implanted. Accordingly, it may be preferable to smooth these exposed peripheral surfaces, or any surface that may engage soft tissue instead of bone or another portion of the implant. Any of the smoothing methods described above could be used. For example, the exposed peripheral surfaces could be machined with a carbide bit as described above.
• The surfaces, including those that are roughened, smoothed or those without any treatment, can be characterized in various ways, such as by determining the static coefficient of friction or by characterizing the surface profile or surface roughness under ISO 4287 (1997).
• First, with respect to the static coefficient of friction,US-A-2009/0292365 discloses that porous metal samples (both commercially pure titanium and Ti-6A1-4V) were machined in the green state. Friction tests were performed using a "sled on a plane" method. The "sled" consisted of the 19 mm x 19 mm (0.75 in x 0.75 in) square metallic matrix samples. Each "plane" was a polymer bone analogue comprising a milled sample of a rigid, closed-cell polyurethane foam with a density of 320 kg.m^-3 (20 lb.ft^-3) (as sold under the trade mark Last-A-Foam 6720 by General Plastics Manufacturing Company, Tacoma, WA). Each sled was connected to a 250 N load cell by 44.5 N (10 lb) monofilament line and pulled at 10 mm.min^-1 for 20 mm (0.8 in). A weight was placed on the sled to create a normal force of 30 N. The static friction coefficient was calculated from the maximum force recorded before the first 0.5 N drop in force.
• The static coefficients of friction with polymer bone analogues for the surfaces were found to be 0.52 for commercially pure titanium that was machined in the green state and 0.65 for Ti-6A1-4V that was machined in the green state, with standard deviations of 0.1. In contrast, porous metal components of the same materials that were blasted as disclosed inUS-A-2009/292365 had average static coefficients of friction with polymer bone analogues of 0.72 to 0.89 for commercially pure titanium and 1.09 to 1.35 for Ti-6A1-4V.
• Thus, a tibial tray made according to the invention may have astem 30, 30A and pegs 32, 34, 36, 38, 32A, 34A, 36A, 38A withdistal surfaces 40, 42, 44, 46, 48, 40A, 42A, 44A, 46A, 48A having a coefficient of static friction (with a polymer bone analogue comprising rigid closed-cell polyurethane foam with a density of about 320 kg.m^-3 (20 lb.ft^-3)) less than 0.7; the outer surfaces of thesepegs 32, 34, 36, 38, 32A, 34A, 36A, 38A andstem 30, 30A near thejunctions 60, 62, 66, 60A, 62A, 66A may have coefficients of static friction (with a polymer bone analogue comprising rigid closed-cell polyurethane foam with a density of about 320 kg.m^-3 (20 lb.ft^-3)) of more than 0.7. Forpegs 32A, 34A, 36A, 38A of the type shown inFIGS. 7,12 to 14 and16, the flatdistal surface 42A, 44A, 46A, 48A may have a lower coefficient of friction; for an extension of the type shown inFIGS. 1,3 to 5 and9, all or part of the spheroidal distal end may have a lower coefficient of friction. Similar results are expected to be obtained with selective etching of the extensions.
• Next considering the surface profile and surface roughness characteristics under ISO 4287 (1997), samples were made from commercially pure titanium metal powder (commercially pure titanium powder, 325 mesh (<45 um), produced by a hydride-dehydride process and that meets the ASTM F-1580 standard, purchased from Phelly Materials, Inc., Bergenfield, New Jersey, Part No. THD325) and produced using the process described inUS-A-2008/1999720. The space filler used in making the samples was sodium chloride (425 to 600 µm). The commercially pure titanium metal powder and salt were mixed, compacted and green-machined. The salt was dissolved out of the machined samples and the samples were then dried. Some of the samples were set aside for surface characterization without sintering. Some of the samples were then sintered. Some of the samples were salt blasted in the green condition using salt (<250 µm NaCl) using the process disclosed inUS-A-2009/292365 and then sintered. Of the sintered samples that were not salt blasted, some of the samples were lightly polished on 400 sanding grit paper and some of the samples were milled after sintering using a milling machine. Some of the sintered samples were SiC ground. Some of the sintered samples were turned on lathes.
• The surfaces of the samples were then characterized using a contact surface profilometer according to ISO 4287 (1997). The characterizations were performed using a Zeiss Surfcomm 5000 contact profilometer with a 2 µm radius ruby ball; the measurement speed was 0.3 mm.s^-1; the tilt correction was least square straight.
• For some of the samples, results were recorded using the "P" values from ISO 4287 (1997). For some of the samples, results were recorded using both the "P" values and "R" values from ISO 4287 (1997). As there described, the "P" values are the primary profile parameters (reference is made to ISO 3274, which defines the primary profile as the "Total profile after application of the short wavelength filter, λs.") and include both roughness and waviness as components of the primary profile; the "R" values are roughness parameters.
• The results of these surface characterizations are shown inFIGS. 33A to 39. Primary profile parameters are shown inFIGS. 33A,34A,35A,36A,37A,38A and39. The column headings starting with the letter "P" (Pa, Pq, Pp, Pv, Pc.1, PDq, Psk, Pku and Pt) all refer to surface profile parameters as defined in ISO 4287 (1997). Roughness parameters are shown inFIGS. 33B,34B,35B,36B,37B and38B. The column headings starting with the letter "R" (Ra, Rz, Rp, Rpmax, Rv and Rt) all refer to surface roughness parameters under ISO 4287 (1997).FIG. 40A is a bar graph illustrating the differences in the average value of the parameter Pa for the green machined, salt blasted, milled, ground, and polished samples, as well as the samples turned on different lathes.FIG. 40B is a bar graph illustrating the differences in the average value of the roughness parameter Ra for the green machined, salt blasted, milled, and ground samples, as well as the samples turned on different lathes. As can be seen fromFIGS. 40A and 40B, the Pa and Ra values of the titanium foam samples can be significantly reduced from the green machined state by milling, grinding and/or polishing the titanium foam, as well as be turning the foam on a lathe. The results are more dramatic when comparing the surface profiles and roughnesses to those of the sale blasted samples.
• The results for some of the surface profile parameters are also provided inUS-A-2009/292365. As there shown the Pa, Pp, Pt and Pq values (as defined in that document) for the samples all at least doubled for the blasted samples as compared to the machined samples with no blasting.
• Since the surfaces of the milled and polished titanium foam samples have lower Pa and Ra values, it is expected that the milled, ground and polished titanium foam samples would have static friction coefficients with polymer bone analogues less than 0.52 ± 0.1 for commercially pure titanium and 0.65 ± 0.1 for Ti-6A1-4V.
• The coefficient of static friction of such a surface is expected to be no greater than those reported inUS-A-2009/292365 for metal foam samples machined in the green state and not subjected to any roughening treatment (0.52 for commercially pure titanium and 0.65 for Ti-6A1-4V, with standard deviations of 0.1). Profile parameters of the peripheral exposed surfaces are also expected to be no greater than the Pa, Pp, Pt and Pq values (as defined inUS-A-2009/292365) for the metal foam samples machined in the green state. It is anticipated that the machining parameters could be adjusted to optimize the surface finishes of the peripheral exposed surfaces anddistal surfaces 40. The exposed porous metal surfaces perpendicular to the bone-engaging surfaces of thefemoral component 12 may be similarly treated.
• An additional effect of smoothing the exposed peripheral surfaces is that the pores will tend to be closed, as discussed above. Reducing the porosity of the exposed peripheral surfaces can be advantageous: if the resected bone bleeds through into the body of the porous metal portion of the implant, the blood will not bleed through the exposed peripheral surfaces into the joint space, thereby eliminating any problems associated with blood in the joint space.
• There are alternative ways of substantially reducing surface roughness of implant surfaces that may come into contact with soft tissue. For example, in the tibial tray illustrated inFIG. 31 (where the same reference numbers have been used as those used in describing corresponding or similar parts in the embodiments ofFIGS. 1,4 to 7,11,18 and20 to 23 followed by the letter "E"), the periphery of thesolid metal portion 80E includes arim 152E that extends to the plane of the bone-engagingsurface 28E. In this embodiment, therim 152E defines a pocket in which the porous metal base 85E is received so that the exposedperipheral surface 150E comprises solid metal. In this embodiment, the tibial tray may be made from a base component, such as a cast component, with pockets configured for cemented fixation, and the pockets could be filled with porous metal, such as a titanium foam, and then sintered.
• FIG. 32 shows another alternative embodiment of a tibial tray (where the same reference numbers have been used as those used in describing corresponding or similar parts in the embodiments ofFIGS. 1,4 to 7,11,18,20 to 23 and31 followed by the letter "F"). In this embodiment, the periphery of thesolid metal portion 80F includes arim 152F that extends to a plane above the plane of the bone-engagingsurface 28F. In this embodiment, therim 152F defines a pocket in which a portion of the porous metal base 85F is received. In this embodiment, the porous metal base 85F is recessed from the periphery of the tibial tray to eliminate contact between the porous metal and soft tissue. Thus, the exposedperipheral surface 150F comprises solid metal. In this embodiment, the tibial tray may be made from a base component, such as a cast component, with pockets configured for cemented fixation, and the pockets could be filled with porous metal, such as a titanium foam, and then sintered. The pockets defined by therim 152F have a depth shown at T₃ inFIG. 32, and the porous metal base 85F has a thickness shown as T₄ inFIG. 32. T₄ is greater than T₃ to ensure that the bone-engagingsurface 28F stands proud so as to ensure that thesurface 28F fully engages and transfers load to the underlying bone.
• Other surfaces of the porous metal component or portion may be advantageously smoothed. It has been found that the strength of the bonding in such sintered assemblies of porous titanium preforms onto a dense titanium substrate is improved when the mating titanium foam surface is machined in a way to smear or close the surface porosity. For example,upper surfaces 86, 86A of thepreforms 85, 85A may be smoothed by machining prior to sintering the preforms to thesolid metal portions 80, 80A to make thetibial trays 14, 14A.
• To characterize the differences in the strengths of the bonds between solid metal and metal foams with different surface characteristics, two foam ring groups were prepared using as-received -325 mesh irregular unalloyed titanium powder (commercially pure titanium powder, as described above). For both foam ring groups, the titanium powder was weighed and combined with granular NaCl space holders that had been sieved into a nominal size range of 425 to 600 µm in a weight ratio to give 80.5% volume fraction NaCl particles. The Ti powder and NaCl space holders were mixed, and the mixture was filled into flexible moulds and compacted in a cold isostatic press. The compressed parts were machined in the green state. The NaCl space holder was then dissolved in water and the parts dried.
• After the foam parts were dried, they were pre-sintered in vacuum at a temperature of 1371 °C (2500 °F) for 4 hours. A hole was then machined through the axial centre of each titanium foam part and the foam parts were then assembled with a line-to-line to slight press fit to pins cut from as-received, 12.7 mm (1.5 in) wrought Ti-6A1-4V titanium alloy bar. The assemblies were then sintered in vacuum for 4 hours at sintering temperature for 8 hours total time.
• The common aspects of the processing of the assembly of the titanium foam and solid titanium alloy parts is summarized in the following table:

  Group	Foam powder material	Space holder nominal size (µm)	Volume fraction NaCl (%)	Sinter temp (°C)	Sinter time (h)
  1	CP Ti	425-600	80.5	1371	4 + 4
  2	CP Ti	425-600	80.5	1371	4 + 4

• TheGroup 1 samples differed from theGroup 2 samples in the manner in which the holes were machined into the rings. The machining processes are summarized in the following table:

  Group	Nominal specimen dimensions (mm)				Foam through hole machining
  	Foam through hole diam	Pin diameter	Foam length	Foam outside diam	Speed (rpm)	Feed (mm/rev)	Tool radius (mm)
  1	12.65	12.68	5	17.25	640	0.076	0.38
  2	12.62	12.68	5	17.23	1000	0.102	0.76

• The machining process forGroup 1 smeared or closed the porosity of the samples, while the machining process forGroup 2 retained a more open surface porosity. Ring shear samples were also prepared for determination of the extent of titanium foam to substrate bonding by image analysis of metallographically mounted and polished cross sections. Although not measured in this example, it is expected that the coefficient of static friction, primary profile parameters (P values) and roughness values of theGroup 1 samples are less than the coefficient of static friction, primary profile parameters (P values) and roughness values of theGroup 2 samples.
• The samples were then tested for shear strength. Testing was performed on an MTS Alliance RF/100 test frame with a 50 kN load cell to which an MTS load platen was attached. A custom made ring shear fixture was attached to the base of the test frame. The fixture had a through hole which provided a small clearance from the test specimen pin diameter. The test specimen was inserted into the through hole until the foam ring contacted the face of the fixture. The specimen was centred within this through hole and the assembly centred under the MTS platen. The MTS was commanded to move the crosshead downward to shear the foam ring from the pin at 2.54 mm.min^-1 (0.1 inch.min^-1) until the peak load was detected. Data was acquired and the stress and strain at 0.2% offset yield and the peak stress were calculated using MTS TestWorks 4.08B software.
• FIG. 41 illustrates that the porous metal-solid metal bond in theGroup 1 samples had greater shear strength than the porous metal-solid metal bond in theGroup 2 samples. Representative mounted and polished cross-sectional images of theGroup 1 andGroup 2 samples are provided inFIGS. 42 and43, which illustrate that the length of the bonded interface between the porous metal portion and the solid metal portion is greater in theGroup 1 samples than in theGroup 2 samples.
• Thus, it may be advantageous to decrease the porosity, static coefficient of friction and surface roughness of: surfaces that may be contacted by soft tissue; surfaces that are difficult to access during a revision procedure; and surfaces that will form a bond with a solid metal portion of an implant component. In other surfaces where bone ingrowth is desirable, surface roughness and static coefficient of friction may be maintained or increased by roughening.
• The invention may be applied to other implant components as well. Bone loss on the proximal tibia or distal femur can make it difficult to properly position and support thetibial component 14, 14A orfemoral component 12 of theimplant system 10 on the bone surface. The prior art has addressed this problem through the use of wedges or augments. Generally, the wedge or augment is placed between part of the bone-engaging surface of the implant component and part of the bone to support part of the implant component on the bone by augmenting part of the bone.
• Due in part to the fact that the size, shape and anatomy of virtually every patient is different, and the variability in the location and amount of bone loss on the proximal tibia, an extensive number of a variety of wedges and augments have been made available to the orthopaedic surgeon. For example, a typical surgical kit will include tibial wedges of different thicknesses and different configurations for use on either the medial or the lateral sides of the tibia.
• The prosthetic knee system orkit 10 may include wedges or augments for both the femoral and tibial sides of the system. These augments may comprise porous metal, and more particularly, a porous metal foam of the same material and made under the same conditions as those discussed above for theporous metal portions 82, 82A, 83 of thetibial trays 14, 14A andfemoral components 12.
• For the femoral side, augments may have features such as those disclosed inUS-5984969 andUS-6005018. For the tibial side, augments may have features such as those disclosed inUS-5019103 andUS-7175665.
• FIG. 24 shows a tibial augment 200 which is made of porous metal across its entire length, width and thickness. The augment 200 includes through-bores 202 sized and shaped to receive portions of pegs or extensions (such aspegs 32, 34, 36, 38, 32A, 34A, 36A, 38A) that may be present, and may be mounted to theporous metal portion 82, 82A of the tibial tray as shown inFIGS. 25 and 26. Frictional engagement of the augment and the pegs or extensions and the porous metal portion of the tray may be sufficient to fix the augment to the tray; otherwise, the augment 200 may include additional through-bores sized and shaped to receive screws (not shown) for fixing the augment 200 to thetibial tray 14, 14A; an illustrative through bore is shown at 204 inFIGS. 24 and25. The augment 200 may also include a recess such asrecess 206 to accommodate any stem (such asstem 30, 30A) on thetibial tray 14. Complementary blind bores may be provided in the tibial tray to receive parts of the screws. The bores in the tibial tray may be threaded, and may be provided in theporous metal portion 82, 82A or may extend through theporous metal portion 82, 82A and into thesolid metal portion 80, 80A. The surfaces defining the through-bores 202, 204 in the augments may be smooth (i.e., non-threaded) and the through-bores 204 for the screws may have top and bottom countersinks so that the augment may be used on either the medial or lateral side, as disclosed inUS-7175665. As shown inFIG. 26, when the augment is mounted on thetibial tray 14A, onesurface 210 of the augment bears againstdistal surface 28A of theporous metal portion 82A of thetibial tray 14A and theopposite surface 212 of the augment 200 becomes the bone-engaging surface of this side of thetibial tray 14A.
• The augment 200 may comprise a porous metal foam. For example, the augment 200 may be made using processes such as those disclosed inUS-A-2008/199720,US-A-2010/098574,US-A-2009/0326674 andUS-A-2009/292365. Exposed peripheral surfaces of the augments, such assurface 250 inFIGS. 25 and 26, may be treated to smooth the exposedperipheral surface 250. The smoothing treatment may comprise, for example, machining as discussed above; alternatively or in addition, thesurface 250 may be masked during any process used to roughen other surfaces of the augment.
• To use the system of the present invention, the surgeon would prepare the distal femur and proximal tibia to receive thebone implants 12, 14, 14A using conventional techniques and implant the tibial tray and femoral component using conventional techniques for cementless components. Thetibial bearing 16 is typically assembled with thetibial tray 14, 14A after thetray 14, 14A has been implanted.
• After implantation, it is anticipated that bone will grow into theporous metal portion 82, 82A of thetibial tray 14, 14A andporous metal portion 83 of thefemoral component 12, including thepegs 32, 34, 36, 38, 39, 32A, 34A, 36A, 38A andstem 30, 30A. If the pegs and stem are made with smoother free ends 40, 42, 44, 46, 48, 51, 40A, 42A, 44A, 46A bone will not, however, grow or grow as vigorously into the smoother free ends. Thus, it is anticipated that there will be bone ingrowth into thedistal surface 28, 28A of thetibial platform 24, 24A andporous metal portion 83 of thefemoral component 12. In addition, bone ingrowth is also anticipated into the exterior surfaces 70, 72, 76, 79, 70A, 72A, 76A of theextensions 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A adjacent to thedistal surface 28 of thetibial platform 24 andporous metal portion 83 of thefemoral component 12 as well as at thejunctions 60, 62, 66, 69, 60A, 62A, 66A. Radial pressure along the proximal exterior surfaces 70, 72, 76, 79, 70A, 72A, 76A is expected to be uniform, to stimulate bone ingrowth in all directions on the stem and pegs 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A. If the free ends 40, 42, 44, 46, 48, 51, 40A, 42A, 44A, 46A of the pegs and stem are smoother (or comprise solid material) than the rest of the porous metal portion, bone is not expected to grow or to grow as vigorously into the smoother exposed exterior surfaces at the free ends 40, 42, 44, 46, 48, 51, 40A, 42A, 44A, 46A of theextensions 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A.
• Theextensions 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A stabilize theimplant component 12, 14, 14A when implanted in a bone of a patient. Thecentral stem 30, 30A provides stability against lift off for the tibial tray. Thepegs 32, 34, 36, 38, 32A, 34A, 36A, 38A surrounding thecentral stem 30, 30A and pegs 39 of thefemoral component 12 provide stability by reducing shear and micromotion, especially after bone ingrowth has occurred.
• If the exposedperipheral surfaces 150, 250 of the implant components are smooth, no soft tissue irritation should occur after the components are implanted and blood should not flow through the porous metal portion into the joint space.
• If it later becomes necessary to remove thetibial tray 14, 14A orfemoral component 12, the surgeon may cut along the distal bone-engagingsurface 28, 28A of thetibial tray platform 24, 24A (or along thedistal surface 212 of an augment 200) to sever the connection between the patient's bone and thetibial tray platform 24, 24A at the interface. If thepegs 32, 34, 36, 38, 39, 32A, 34A, 36A, 38A andstem 30, 30A consist of porous metal foam across their entire thicknesses T1 and T2, the surgeon may also cut through all of theextensions 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A at thejunctures 60, 62, 66, 69, 60A, 62A, 66A of theextensions 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A and thedistal surface 28, 28A of thetibial platform 24, 24A and bone-engagingsurfaces 13, 15 of thefemoral component 12 using a bone saw and easily remove thetibial platform 24, 24A andfemoral component 12. Such a result is generally not possible with pegs and stems made of solid titanium or cobalt chromium alloy, since bone saws cannot generally cut through solid metal. To remove theextensions 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A, the surgeon may then cut around the outer perimeter of eachextension 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A to sever the connection between the bone and theextensions 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A. Such cuts around the perimeters may be made, for example, through use of a trephine saw. Eachextension 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A may then be readily removed. Notably, if the free ends of the extensions are smooth, little or no bone ingrowth will have occurred at the ends of the extensions, so the removal of the stem and pegs should be made easier.
• As indicated above, sawing through the stem and pegs 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A, 30D, 32D, 36D, 30E, 32E, 36E is made easier if the stem and pegs at thejunctions 60, 62, 66, 69, 60A, 62A, 66A, 60D, 62D, 66D, 60E, 62E, 66E consist of porous metal rather than solid metal. Generally, it is believed that the stem and pegs may be cut through transversely with a standard surgical saw if the material is 25 to 35% of theoretical density. Notably, in the illustrated embodiments, thetitanium alloy studs 132, 134, 136, 138, 140, 132A, 134A, 136A, 138A, 140A, 134D, 134E do not extend beyond the plane of bone-engagingsurface 28, 28A, 28D, 28E; therefore, in cutting through theextensions 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A, 30D, 32D, 36D, 30E, 32E, 36E, the surgeon need not cut through thesolid metal studs 132, 134, 136, 138, 140, 132A, 134A, 136A, 138A, 140A, 134D, 134E.
• It is anticipated that a standard surgical saw could cut through a somewhat more dense material. In addition, it is anticipated that a standard surgical saw could cut through a composite of materials, such as a small diameter central core of solid metal (e.g. titanium alloy) surrounded by a porous metal foam (e.g. commercially pure titanium). Accordingly, although for purposes of ease of removal, it is preferred that the entire thicknesses of the extensions be porous metal at the junctions, other considerations may call for a composite of materials to be used.
• Thus, the present invention provides a knee prosthesis with a tibial implant component and femoral component suitable for optimized cementless fixation. Soft tissue irritation and bleed-through may be substantially reduced or eliminated. The strength of a sintered bond between porous and solid metal portions of an implant component may be optimized. Moreover, the implant components may be readily removed from the bone in revision surgery to conserve native bone.
• The present invention is applicable to other joint prostheses as well. An example of such a joint prosthesis is shown inFIG. 27. The joint prosthesis ofFIG. 27 is an ankle prosthesis which comprises atalar component 312, a compositedistal tibial component 314 and abearing 316. In this particular embodiment, the compositedistal tibial component 314 comprises a distalsolid metal portion 320 and a proximalporous metal portion 322, sintered together as described above for theknee prosthesis 10. As in theknee prosthesis 10, thesolid metal portion 320 and the bearing may have mounting surfaces with complementary locking features (not shown) so that the bearing 316 can be fixed to thesolid metal portion 320 of thetibial component 314. Thedistal tibial component 314 has aproximal extension 324 extending proximally from the bone-engagingsurface 326 of thetibial component 314. Theproximal extension 324 may provide porous metal outer surfaces for engaging the bone or thedistal portion 328 may comprise porous metal and theproximal portion 330 comprise porous metal with a porosity or reduced coefficient of static friction as described above. A similar extension could be provided in the talar component if desired.
• The number and configurations of the extensions may be varied. For a tibial tray, for example, the tray could include pegs but no central stem. Although the illustrated tibial trays have four pegs, fewer pegs may be acceptable.
• Other variations are possible as well. For example, theextensions 30, 32, 34, 36, 38, 39, 30A, 32A, 34A, 36A, 38A, 30D, 32D, 36D, 30E, 32E, 36E could be made as modular components to be assembled with a base plate intraoperatively if desired. The base plate could comprise a porous preform like that shown inFIG. 8 at 85 sintered to a solid metal portion such as that shown at 80 inFIG. 5. The threaded and Morse taper connections described above should be sufficient to hold the components together without sintering, particularly if the studs are longer, as shown in the embodiment ofFIGS. 28 to 30. The extensions and base plate may be provided in a kit form, with the base plate and extensions being discrete components as shown inFIGS 8, 9 and17 to 20; the extensions in the kit could have differing properties, such as size or surface finish, and the surgeon may chose the most appropriate extension for the particular patient intraoperatively. For example, a set of extensions could be provided with porous distal ends and a second set of extensions could be provided with smooth distal ends to accommodate surgeon preference.

Claims (15)

1. A tibial tray implant component of a knee prosthesis comprising a solid metal portion, and a porous metal body having a void space of at least 60% by volume and proximal and distal principal surfaces, the proximal principal surface of the porous metal body being bonded to the solid metal portion and the distal principal surface of the porous metal body providing the distal bone-engaging surface of the tibial tray, the porous metal body having a peripheral surface which extends generally perpendicularly from the distal principal surface to the proximal principal surface, the peripheral surface of the porous metal body having a static coefficient of friction which is lower than that of the distal principal surface.
2. The orthopaedic implant component of claim 1 in which the peripheral surface of the porous metal body has been smoothed so as to reduce its roughness.
3. The orthopaedic implant component of claim 1 in which the porous metal body comprises an extension extending distally from the tibial tray to a free distal end, and the free distal end of the extension defines a third surface of the porous metal body, the static coefficient of friction of the third surface being lower than that of the bone-engaging surface provided by the porous metal body.
4. The orthopaedic implant component of claim 3 in which the extension comprises

   (a) a peg spaced from the central sagittal plane of the tibial tray, or (b) a stem positioned along the central sagittal plane of the tibial tray.
5. The orthopaedic implant component of claim 1 which includes a tibial augment comprising porous metal, the tibial augment having a proximal principal surface which can be positioned against the distal principal surface of the porous metal body and a distal principal surface which provides the distal bone-engaging surface of the tibial tray.
6. The orthopaedic implant component of claim 5 in which the augment has a peripheral surface which has been treated so as to make it more smooth.
7. An orthopaedic implant component comprising a porous metal body having a bone-engaging surface and a second surface extending from the bone-engaging surface, in which the bone-engaging surface has a static coefficient of friction and the second surface has a lower static coefficient of friction and in which the body has a void space of at least 60% by volume.
8. The orthopaedic implant component of claim 7 in which the implant component comprises a tibial tray having a solid metal portion and in which:

   the porous metal body is bonded to the solid metal portion;

   the bone-engaging surface of the porous metal body comprises the distal surface of the tibial tray;

   the second surface extends around the periphery of the tibial tray and connects the solid metal portion to the bone-engaging surface of the body.
9. The orthopaedic implant component of claim 7 in which the second surface includes opposite portions, and the porous metal body between the opposite portions of the second surface comprises metal foam.
10. The orthopaedic implant component of claim 7 in which the implant component comprises a tibial tray, the implant component further includes a solid metal support portion, the porous metal body comprises an extension extending distally from the tibial tray to a free distal end, and the free distal end of the extension defines the second surface of the porous metal body.
11. The orthopaedic implant component of claim 10 in which the extension comprises

    (a) a peg spaced from the central sagittal plane of the tibial tray, or (b) a stem positioned along the central sagittal plane of the tibial tray.
12. The orthopaedic implant component of claim 7 in which the implant component comprises a distal femoral component, the implant component further includes a solid metal support portion, the porous metal body comprises an extension extending proximally from the tibial tray to a free proximal end, and the free proximal end of the extension defines the second surface of the porous metal body.
13. The orthopaedic implant component of claim 12 in which the extension comprises a peg spaced from the central sagittal plane of the distal femoral component.
14. The orthopaedic implant component of claim 7 in which the implant component is part of an orthopaedic implant system including a second implant component having a bone-engaging surface and the orthopaedic implant component comprises an augment configured to be selectively placed against the bone-engaging surface of the second implant component.
15. The orthopaedic implant component of any of the above claims in which the first surface comprises a bone-engaging surface having a surface porosity and the second surface has a lower surface porosity.

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